JET GROUTING METHODS USED TO IMPROVE THE

CONSTRUCTABILITY OF TRENCHLESS PROJECTS

Brennon T. Morioka1, Ph.D., P.E.
James K.P. Kwong2, Ph.D., P.E.,
Jeff K. Kalani3

ABSTRACT
The use of jet grouting methods for ground improvement was a key factor in the success of
microtunneling beneath the busiest parts of downtown Honolulu and horizontal directional
drilling (HDD) across Honolulu Harbor. Located in and near the Honolulu Harbor area, general
subsurface conditions along a 0.9-km long, 1,372-mm diameter and a 2.3-km long, 914-mm
diameter gravity sewer alignments, and a 1.5-km long, 864-mm and 1,219-mm diameter force
mains included coralline, lagoonal, estuarine, volcanic, and fill deposits. Jet grouting aided in
microtunneling operations, groundwater control for jacking and receiving shafts, utility
protection, resolving unexpected utility conflicts within shafts, and pipeline and manhole support
in settlement sensitive areas along major, highly congested utility corridors. For the HDD harbor
crossing, jet grouting to about –40 m elevation allowed for protection of existing container yard
pier piles against potential ground loss due to running and flowing ground conditions below the
end-bearing piles. QA/QC measures employed to evaluate the effectiveness of the ground
improvement program included monitoring of jet grouting operations, coring of jet grout
columns and strength tests.

Keywords: trenchless technology, microtunneling, horizontal directional drilling, jet grouting,

ground improvement, sewers, force mains, shaft construction

1
Sr. Geotechnical Engineer, URS Corporation, Honolulu, HI; brennon_morioka@urscorp.com
2
Vice President, URS Corporation, Honolulu, HI; james_kwong@urscorp.com
3
Geotechnical Engineer, URS Corporation, Honolulu, HI; jeff_kalani@urscorp.com
INTRODUCTION
Jet grouting ground improvement methods have been specified on two successful microtunneling
projects in downtown Honolulu and one project completed using both microtunneling and HDD.
The first microtunneling project outside the Downtown Honolulu area involved the
reconstruction of about 0.9 kilometers (3,000 feet) of 1,372-mm (54-inch) reinforced concrete
gravity collection sewer installed along a major city highway (Honke et al., 1997). The second
microtunneling project, which was constructed in the heart of Downtown Honolulu, the most
congested area in Hawaii, involved the installation of a new 914-mm (36-inch) reinforced
concrete gravity sewer pipeline, approximately 2.3 kilometers (7,500 feet) long (Kwong et al.,
1998, Kwong et al., 1999). The second sewer reconstruction project also involved the
construction of thirty-six manholes, extensive utility relocation, and twenty-four hour by-pass
systems. The third trenchless project was completed using both microtunneling and HDD
installation methods. HDD was used to construct two parallel force main lines beneath Honolulu
Harbor, the most traveled waterway in Hawaii, from the Downtown Honolulu end of the harbor
and under a shipping container yard and pier on Sand Island. High density polyethylene (HDPE)
pipes 864-mm (34-inches) in diameter were pulled across the harbor through 1,219-mm (48-
inch) steel casings approximately 0.7 km (2,300 feet) in length. Microtunneling methods were
used to install an additional 0.8 km (2,500 feet) of 1,219 -mm (48-inch) glass-fiber reinforced
pipe from the HDD exit point in the container yard to the Sand Island Wastewater Treatment
Facility (WWTF).

Jet grouting methods were specified for the microtunneling projects to serve multiple purposes
(Kwong et al., 1999; Morioka et al., 2001). Jet grout columns were used to support the new
sewer line and manholes to prevent future settlements of the collection system that may occur in
the highly compressible underlying soils and to change very soft soils to cemented zones,
eliminating the possibility of MTBM settlement and uncontrollable deviation from line-and-
grade. Jet grout bottom plugs and jet grouted zones around and between gaps in the sheetpile
shoring systems caused by utility conflicts, as well as at all MTBM ingress/egress locations,
were used for groundwater control within the jacking and receiving shafts. Jet grouted zones
also provided resistance against lateral deflections to protect a nearby existing, historical, rock
seawall from jacking loads.

Jet grout was also installed to depths of 43 meters (140 feet) below Mean Sea Level (MSL) at
and above the anticipated HDD drill path beneath end-bearing pile supported pier to reduce the
potential of settlements of the pier due to running or flowing conditions around the slurry filled,
opened reamed hole during hole enlargement and prior to pipe pullback operations.

SUBSURFACE CONDITIONS
The geologic formation and history of the Hawaiian Islands is one of dynamic change and
fluctuation. The resulting regional geology in the coastal areas of Oahu consists of a volcanic
basalt island core that is flanked by beaches and coral reefs, which are locally dissected by
erosional channels, estuaries, lagoons, and new lava flows. The mixing and interfingering of
coral, beach sands, estuarine and lagoonal deposits with lava flows, and occasional deposits of
alluvial silts and clays carried down from the mountains have created a local geology that is
highly complex.
JET GROUTING REQUIREMENTS

Specification requirements
The plans and specifications for the first two microtunneling projects required jet grout columns
to be installed with a minimum 1.2-meters (4-feet) diameter and 690 kPa (100 psi) unconfined
compressive strength (UCS). All the described microtunneling projects specified jet grouting
methods be used to install shaft bottom seals in soils, and for MTBM ingress and egress. The
HDD portion of the third project also called for jet grout columns to be installed to depths up to
43 meters (140 feet) below MSL at and around the HDD drill path beneath the pile support pier
at the shipping container yard. Minimum UCS values for this jet grouted zone was 4,826 kPa
(700 psi). This jet grouted zone was to provide a degree of ground stability around the reamed
hole area to reduce the potential of running or flowing ground into the open reamed hole and the
amount of potential settlement below the existing end-bearing piles.

The geotechnical reports for these projects indicated jet grouting methods would not be effective
in cemented soils or rock, and placement of a tremie concrete plug and other grouting methods
would be required to control groundwater inflows into shafts.

For the two Downtown projects, a sequence of alternating and overlapping primary and
secondary jet grout columns was designed to provide support for the pipeline and produce a
more uniform material at the tunneling zone for the microtunnel boring machine (MTBM) to
improve steerability (Figure 1). The specific design requirements for jet grout column
installation for pipe support are provided in Kwong et al. (1999) and Morioka et al. (2001). The
overlapping of jet grout columns, installed using single fluid jet grouting methods, provided a
generally continuous and more consistent tunneling zone of soil-cement through which the
MTBM could excavate and make steering adjustments, in otherwise very soft estuarine and
lagoonal silts (typical SPT and California sampler N-values of 0 to 5 blows per foot). The size
of the jet grout columns appeared to provide sufficient lateral coverage, such that the MTBM
would remain within the jet grouted zone, as long as the MTBM did not deviate from the
alignment in excess of the specified line and grade tolerances.

Microtunneling considerations
Successful installation of the specified jet grout columns appeared to have increased the
efficiency of microtunneling operations (Morioka et al., 2001). Line and grade were maintained
within the specified tolerances without observable, significant steering adjustments in these
projects. Jet grouting the microtunneling zone also aided in maintaining lower and fairly
constant jacking forces (Morioka et al., 2001). Jacking forces during tunneling within jet
grouted zones typically ranged between 270 to 450 kN (30 to 50 tons) as compared to 530 to 890
kN (60 to 100 tons) in non-grouted alluvium, coralline deposits, and coral reef materials. Soil
improvement was also required behind the jacking pit reaction/thrust block locations where soft
and loose subsurface materials were present to reduce potential lateral ground deformation or
bearing failure behind the thrust block during pipe jacking operations (Kwong et al., 1998).

Figure 2 shows the line and grade observations for a drive with and without jet grout in the same
drive. Tunneling in a loose, unfused portion of volcanic cinder deposits (flowing sands) posed
initial steering difficulties resulting in significant line deviations, as illustrated in Figure 2.
However, the operator was able to steer the machine back on line once the MTBM entered the jet
grouted zone, as steerability improved due to the availability of ground resistance from the jet
grouted soils.

Sewer pipe and manhole support

The geotechnical explorations indicated that highly compressible, subsurface deposits underlie
numerous portions of the two Downtown Honolulu sewer alignments and a short segment of the
Sand Island project. Concerns existed that the placement of compacted backfill at shaft
excavations and groundwater drawdown from future construction activities would induce new
loads on the compressible soils beneath the manholes and pipelines. This would potentially
result in settlements that may create sags and reverse flows within the new gravity sewer
collection system, as well as potential cracking at manhole/pipe connections if no preventative
measures were taken.

Figure 1. Jet grout for pipe/manhole support, groundwater control, and microtunneling

To reduce the potential for future settlement of the new manholes and sewer pipes, the
compressible soils beneath the manhole subgrade and the sewer line were stabilized by installing
jet grout columns that extended into a firm bearing layer (Figure 1) to maximum depths of 24
meters (80 feet) below ground surface. Primary columns were installed to behave as a type of
deep foundation support system (Kwong et al., 1999; Morioka et al., 2001). The columns were
designed to carry the load of the newly installed sewer pipe under full flow conditions, in
addition to the weight of the soil above the pipe, the jet grouted zone around the pipe, and the jet
grout column itself.
Shaft construction and groundwater control considerations
Groundwater control was also a key factor in the construction of shaft and trench excavations
and in determining appropriate excavation support systems. Due to the requirement that
precluded dewatering methods for groundwater control using wells, a watertight support system
was required (Kwong et al., 1998). Lowering of the groundwater table outside of any excavation
limit was strictly prohibited due to the very loose and soft, highly compressible subsurface
conditions of the downtown, high-rise areas, and the stringent environmental regulations on
dewatering discharge.

Coralline Jet Grout Zone

Deposits Cinders Lagoonal Alluvium

30

-30 Line
Grade
-60
0 50 100 150
Distance (m)

Figure 2. Line/grade observations in jet grouted and non jet grouted materials

For the downtown project, continuous interlocking sheetpiles in conjunction with overlapping jet
grout columns with appropriate internal bracing systems were specified. Also, because the
excavations did not penetrate into impervious deposits, the soils below the base of the shaft were
treated utilizing jet grouting methods in order to establish a groundwater cut-off at the base of the
excavation, to prevent excavation instability, and to avoid excessive groundwater inflows. In
selecting, designing, and constructing shoring systems for the shaft excavations, the contractors
had to consider the presence of low to moderate strength sand, gravel, and clay layers below the
groundwater table in designing against potential bottom heave and boiling, as well as the
presence of strong, cemented, coral reef formations with cobble- and boulder-sized fragments.

Where conflicting adjacent existing utilities were too close to allow the installation of sheetpiles,
and too costly to be relocated, jet grouted columns were installed to strengthen and close the
shaft walls and cut off groundwater inflows prior to shaft or trench excavation. Excavation of
these shafts and support/protection for some of these utilities were accomplished by the
innovative use of combined steel micro-piles installed within 1.2- to 2.4-meter (4- to 8-feet)
diameter jet grout columns beneath the ducts. Double fluid methods were used to install the
larger diameter jet grout columns. In areas of conflicting utilities, the contractor was also
instructed to pre-drill and break-up cemented soils and rock, prior to jet grouting beneath large
utilities.
In addition, the close proximity of an eighty year-old, river rock seawall near a jacking pit
dictated the installation of jet grout columns behind the thrust block that successfully reduced the
amount of lateral deflection that may have resulted in cracking of the rigid seawall. The jet grout
column layout (Figure 3) was designed to resist against shearing forces through the columns and
translation and deflection of the grouted mass.

Jet grout stabilized soils were also used to control groundwater inflows for MTBM
ingress/egress locations around the shaft excavations. A jet grouted zone beyond the anticipated
excavation limits of the MTBM was installed to provide groundwater infiltration control at the
MTBM ingress/egress locations within the sheetpile walls, as well as to reduce the amount of
flowing and running ground into the excavation. Ground loss below the groundwater table and
the shallow amount of ground cover of 2.4 to 4.6 meters (8 to 15 ft) was a serious concern of the
engineers and owner, should this condition propagate towards the ground surface.

Figure 3. Jet grout layout for rock sea wall protection and inclinometer data

Jet grouting below pier pile foundation system

Jet grout was used to help stabilize the influence zone below a pile-supported pier for HDD
beneath the Honolulu Harbor crossing (Figure 4). The pier was supported by end bearing piles
in medium dense to dense, coralline deposits. The drill path was expected to contain high
contents of gravels and sands with coralline cobbles and boulders or cemented zones. Cobbles
and boulders falling into the 1,524-mm (60-inch) open-reamed hole would create potential
obstructions during pullback activities. In addition, if ground loss as a result of running and/or
flowing ground conditions developed around the open hole and propagated up towards the pile
tips, a loss in load carrying capacity of the end-bearing piles could result in excessive settlements
of the piles. The pier supported by the piles contained crane rails for the 890 kN (100-ton)
Gauge Cranes that load and unload the cargo ships. The cranes were extremely settlement
sensitive and, for this reason, no settlement of the crane rails was allowed by the third-party, pier
owners. The jet grouted zone, installed by double fluid jet grouting methods (selected by the
contractors), around and above the drill path was designed to compensate for the absence of
ground material as close as 3.0 meters (10 feet) below the pile tips. Figure 5 shows jet grouting
operations on the pier area.

Figure 4. Jet grouted zone below pier piles

Figure 5. Jet grout activities on Container yard Pier, Honolulu Harbor

QA/QC PROGRAM

Jet grout testing program

Prior to production column installation on these projects, the contractors were required to
demonstrate that the jet grouting construction methods and equipment used for this project were
suitable for the anticipated ground conditions and would satisfy the depth, diameter, overlapping,
and material property requirements outlined in the project specifications and shown on the
contract drawings. A more detailed description of a typical test program is provided in Morioka
et al. (2001).

Jet grout test programs were performed at selected locations along the alignments of each
project. The test program sites were selected based on the types of anticipated subsurface ground
conditions to be encountered to evaluate the effectiveness of jet grouting methods in the various
soil materials and depths.

The upper 1.5 meters (5 feet) of the test columns were exposed to determine actual in-situ
column dimensions and conditions. An example of exposed, top portion of the jet grout test
columns from the various test programs are shown in Figures 6 and 7. Bulk specimens from
exposed columns and core samples from selected columns and selected locations within and
between columns were collected for laboratory testing. Results from the UCS testing program
for representative samples at selected depths are presented in Figure 8.

Figure 6. Exposed test column from Downtown Honolulu project

Core samples at the edge and in the overlap zones were used to demonstrate the quality of the
grouted material in the installed columns. Core samples were examined for continuity,
segregation, and quality of grouted material. In general, core recovery ranged from 85 to 100
percent and Rock Quality Designation values were typically on the order of 70 to 100 percent.
Photographs of core samples from a 23-meter (75-foot) jet grouted primary column from the
second Downtown Honolulu project are shown in Figure 9.
 (a) (b)
Figure 7. Exposed test column from Sand Island project
(a) 0.9-m diameter test column by double fluid methods,
(b) Top portion of 1.0-m diameter columns installed by single fluid methods

Unconfined Compressive Strength (kPa)

0 5,000 10,000 15,000 20,000 25,000
0

10

15 Mixed with:

20 Alluvium (SM to MH)

Coralline Sand & Gravel (GM to GP)
25 Estuarine/Lagoonal (SM, GM, MH)
Coralline Sand & Gravel (DF)
30

35

Figure 8. Selected QA/QC test core strength results

(DF – double fluid methods, others single fluid methods)

Figure 10 shows QA/QC cores from the Sand Island project in coral detritus and partially
cemented reef formations. Figures 10(a) and 10(b) illustrate the jet grout material intermixed in
voids, cavities, and joints in the coral formation within the expected grout zone. Appropriate
adjustments in jet grouting parameters, such as lift rate, rotation, grout pump pressures, air flow
and pressures, number of grouting nozzles, and cement grout specific gravity are very important
in achieving the desired results in variable ground conditions and when large ranges in depths
and groundwater pressures are expected.

Field permeability tests were also performed in the test core holes to evaluate the permeability of
the grouted zones. Calculated in-situ hydraulic conductivities of jet grout soils ranged from
1x10-6 to 1x10-7 cm/sec (2x10-6 to 2x10-7 ft/min).

Ground heave measurements were also observed during the test programs to determine the
amount of ground movement during column installation. Observed ground heave measurements
from the test programs were less than 50 mm (2.0 inches) for the columns installed up to 1.2
meters (4 feet) below ground surface. However, observed ground heave during deeper
production column installation, between 3.0 to 4.6 meters (10 to 15 feet) below ground surface,
was less than about 13 mm (½-inch).

S am p le# : S TA 4 5 + 1 4 S am p le# : S TA 4 5 + 1 4
D epth: 5 ’ to 1 0 ’ D epth: 2 0 ’ to 2 5’
1 5 ’ to 2 0’ 3 0 ’ to 3 5’

S am p le# : S TA 4 5 + 1 4 S am p le# : S TA 4 5 + 1 4
D epth: 3 5 ’ to 4 5 ’ D epth: 4 5 ’ to 5 5 ’

S am p le# : S TA 4 5 + 1 4
D epth: 6 0 ’ to 6 5’
7 0 ’ to 7 5’

Figure 9. Representative test core samples from Downtown Honolulu project

 (a) (b)

(c)
Figure 10. Representative test core samples from Sand Island project

Daily QA/QC monitoring program

Throughout the jet grouting operations, QA/QC monitoring was performed by the construction
management design team to observe and record installation parameters used for the production
columns. Morioka et al. (2001) provides a more detailed description of daily jet grouting
observations and records.

Analyses of QA/QC core tests appeared to demonstrate certain trends in UCS values obtained,
depending on in-situ material type and depth. As illustrated in Figure 8, jet grouting in granular,
coralline deposits typically resulted in higher UCS values. Estuarine and lagoonal deposits,
consisting predominantly of silts and clays, typically produced the lowest UCS values upon
QA/QC testing. The more granular alluvial deposits, although consistently lower in strength
when compared to jet grout cores from coralline deposits, produced UCS values higher than the
silty and clayey estuarine and lagoonal deposits at similar depths. In most cases, decrease in
strength values was observed in tests performed on core samples retrieved from greater depths.
In general, jet grout UCS values in coralline materials were reported to be as high as 15,000 kPa
(2,175 psi), 6,000 kPa (870 psi) in granular alluvium, and 4,300 kPa (600 psi) in the estuarine
and lagoonal deposits.

Surface settlement surveys were also performed periodically along the alignment at the pier
location because of the settlement sensitive nature of the crane rails situated on the pier. In
general, survey data obtained prior to jet grouting, and before and after HDD operations,
indicated little to no settlement at the pier surface. The jet grout was installed prior to drilling of
the pilot holes.

SUMMARY AND CONCLUSIONS

Based on the observations during construction of the three projects described in this paper, jet
grouting can be a useful and multi-purpose ground improvement technique to reduce potential
construction difficulties relating to microtunneling, shaft installation and HDD. Jet grouting
methods aided in the construction activities for reducing groundwater infiltration from both the
excavation walls and shaft bottoms, particularly where the shaft wall cannot be closed, due to the
presence of existing utilities and other pipelines, to a depth of 12 meters (40 feet) below ground
surface and for improving excavation bottom stability by increasing strength characteristics of
the in-situ soils. Steering control during microtunneling was improved by producing more
uniform tunneling conditions where mixed face and/or adverse tunneling conditions pre-existed.

Jet grouting provided stabilized potential problematic ground conditions, to reduce potential
adverse effects to an existing pier pile foundation system prior to HDD and adequate protection
of existing utilities and historic structures near shaft excavations. Finally, jet grouting was useful
in providing long-term pipe support against excessive settlements due to consolidation of the
highly compressible soils in the project areas.

Adequate QA/QC efforts were found to be vital in the evaluation and aid in the proper
installation of effective jet grout columns, particularly for the deep columns, such as the 21 meter
(70 feet) long grouted length installed to depths of up to 24 meters (80 feet) below ground
surface for pipeline support and microtunneling, and where jet grouting had to be performed in
an unprecedented depth of 40 meters (130 feet) below sea level.

The benefits of ground improvement with jet grouting techniques are many and can be very cost-
effective when used on large projects and/or for multiple construction purposes. However,
adequate, performance-base specifications, an experienced contractor work fore, and careful
monitoring and control of jet grouting procedures are vital to the success of jet grouting in highly
diverse and difficult geological conditions, such as those described. Test programs should be
adequately defined and planned to ensure compatibility of the equipment and installation
methods with the full range of anticipated ground conditions.

REFERENCES
[1] Kwong, J., S. Klein, G. Nagle, and S. Duke (1998). “Microtunneling in Downtown
Honolulu,” Proceedings from Pipelines in the Constructed Environment, ASCE Specialty
Conference, San Diego, 1998.

[2] Kwong, J., S. Klein, G. Nagle, G. Okita, and S. Duke (1999).“Microtunneling Under
Honolulu,” Civil Engineering, ASCE, March, Volume 69, No. 3.

[3] Morioka, B.T., J.K.P. Kwong, and J.K. Kalani (2001). “ Jet Grouting for Microtunneling
and Shaft Construction in Highly Congested Utility Corridors,” Proceedings from 2001 –
A Geo-Odyssey, Foundations and Ground Improvement, ASCE Specialty Conference,
Blacksburg, VA, June 9-13, 2001.
ACKNOWLEDGEMENT
Jet grouting and relating work for the downtown Honolulu projects was performed by Hayward
Baker (first project) and Layne GeoConstruction (second project) and Frank Coluccio
Construction (general contractor); jet grouting for the HDD crossing was performed by Layne
GeoConstruction for Modern Continental Construction (general contractor).